BEFORE SERVICING THE UNIT, READ THE "SAFETY. PRECAUTIONS" IN .....
CONTENTS. - 2-. Please read the followings before servicing your refrigerator. 1.
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REFRIGERATOR SERVICE MANUAL CAUTION BEFORE SERVICING THE UNIT, READ THE "SAFETY PRECAUTIONS" IN THIS MANUAL.
MODEL: GR-S462/GR-S512
CONTENTS SAFETY PRECAUTIONS ....................................................................................................................................................... 2 SERVICING PRECAUTIONS.................................................................................................................................................. 3 SPECIFICATIONS................................................................................................................................................................... 4 PARTS IDENTIFICATION ....................................................................................................................................................... 5 DISASSEMBLY.................................................................................................................................................................... 6-7 DOOR................................................................................................................................................................................... 6 DOOR SWITCH.................................................................................................................................................................... 6 THERMISTOR ...................................................................................................................................................................... 6 FAN AND FAN MOTOR........................................................................................................................................................ 6 DEF' CONTROL ASM .......................................................................................................................................................... 7 LAMP.................................................................................................................................................................................... 7 CONTROL BOX-R................................................................................................................................................................ 7 ADJUSTMENT..................................................................................................................................................................... 8-9 COMPRESSOR.................................................................................................................................................................... 8 PTC-STARTER..................................................................................................................................................................... 8 OLP (OVER LOAD PROTECTOR) ...................................................................................................................................... 9 CIRCUIT DIAGRAM................................................................................................................................................................ 9 TROUBLESHOOTING..................................................................................................................................................... 10-15 COMPRESSOR AND ELECTRIC COMPONENTS ........................................................................................................... 10 PTC AND OLP .................................................................................................................................................................... 11 ANOTHER ELECTRIC COMPONENTS ............................................................................................................................ 12 SERVICE DIAGNOSIS CHART.......................................................................................................................................... 13 REFRIGERATING CYCLE ............................................................................................................................................ 14-15 DESCRIPTION OF FUNCTION & CIRCUIT OF MICOM ................................................................................................16-32 EXPLODED VIEW ........................................................................................................................................................... 33-35 REPLACEMENT PARTS LIST ............................................................................................................................................ 36-
SAFETY PRECAUTIONS Please read the followings before servicing your refrigerator. 7. When you stand up during observing the lower part with the upper door open, move with care to prevent head wound which may happen by hitting the upper door.
1. Check if an electric leakage occurs in the set. 2. To prevent electric shock, unplug prior to servicing. 3. In case of testing with power on, wear rubber gloves to prevent electric shock.
8. When sloping the set, remove any materials on the set, especially thin plate type. (ex.: glass shelf or books.)
4. If you use any appliances, check regular current, voltage and capacity.
9. When servicing evaporator part, wear cotton gloves without fail. It is to prevent wound by sharp fin of evaporator.
5. Don't touch metal products in cold freezer with wet hand. It may cause frostbite. 6. Prevent water flowing to electric elements in mechanical parts.
10. Leave a breakage of refrigerating cycle to a heavy service center. The gas in cycle inside may soil ambient air.
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SERVICING PRECAUTIONS vacuum operation is over, add the quantity in grams of R134a to the refrigerant system. Remember that every system has an exact quantity of R-134a with a tolerance of ±5 grams that can be added. (Figure 4)
Air Recharging in Compressor Test the refrigeration by connecting it electrically before refilling operation. It is necessary to ascertain the function of the motor-compressor and identify the defects immediately. If the defects have been found, empty the old system of eventual R-134a residue by breaking off the end of the extension piece at its narrow point. (Figure 1) Replace the filter and any damaged components. Unsolder and pull off the piece remaining inside the service tube and then attach an extension completely with male Hansen and last, solder it to the same tube again. (Figure 2) POINT TO BE BROKEN
TO THE R-134a CYLINDER
CHARGE TUBE EXTENSION
FEMALE HANSEN
TO THE REFRIGERATION SYSTEM
MALE HANSEN SERVICE TUBE EXTENSION
Figure 4
SOLDERING POINT
Figure 1
Before performing this operation (if the vacuum pump and refilling cylinder are connected), make sure that the valve placed between the vacuum pump and refilling tube are closed to keep the Freon for adding to the system. (Figure 5)
Figure 2
It is necessary to execute the soldering operation with valve open so that the fumes caused by oil residue can come out freely without blowholes between two tubes during heating the point to be soldered. The extension fitted with the male Hansen is connected to the female fitting of the vacuum pump tube. (Figure 3)
FILLING OR CHARGE TUBE
VALVE TO BE OPENED WHEN REFILLING
TO THE REFRIGERATION SYSTEM
TO THE CHARGE CYLINDER
VALVE TO BE CLOSED AFTER VACUUM
TO THE VACUUM PUMP TO THE VACUUM PUMP PRESSURE GAUGE
Figure 5
In addition, check the graduated scale on the cylinder for the quantity of R-134a to be added, for example, if we have 750 grams of Freon in the cylinder and must add 165 grams to the group, this amount will be reached when R134a has dropped to 585 grams, remembering that the indicator shows a lower limit of meniscus. Do this after choosing the scale corresponding to the gas pressure different scales reported as the same gas pressure indicated by the pressure gauge on the top of the column. To make R-134a flow into the system, open the valve placed at the base of the cylinder and connected to the filling tube. The amount of Freon cannot be added to the system all at once because it may cause a blocking of motor-compressor. Therefore, proceed by adding original quantity of about 20-30 grams and close the valve immediately. The pressure rises and the motor-compressor must start, sucking the gas and making the pressure go down again. Regulate the valve again, maintaining the same manner until reaching to the quantity of R-134a established for the system being charged. When the system is running, the suction pressure must be stabilized between 0.30 to 0.6 atmosphere.
Figure 3 Air evacuating from the system begins so soon as the pump starts. The refrigeration system must be kept under vacuum until the reading on the low-pressure gauge indicates vacuum (0 absolute, -1 atm., -760 mm hg) in any case it is advisable to keep the pump running for about 30 minutes. (Figure 3) In case that a considerable leakage occurs and to stop the vacuum pump will be necessary and add a small quantity of Freon to the system, if vacuum should not be obtained (pressure gauge can't fall to 1 atmosphere), start the refrigeration unit and find the leakage with the special leakfinder. When the defective soldering point is visible, re-do it after opening the extension tube valve and reestablishing the normal outside pressure inside the group. Because the melted alloy is sucked into the tubes and block them, the pressure must be rebalanced when vacuum is in the system in soldering. As soon as the
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1. SPECIFICATIONS SPECIFICATIONS
ITEMS
FREEZER NET CAPACITY REFRIGERATOR (l) TOTAL DIMENSIONS (mm) NET WEIGHT (kg)
GR-S512Q/GR-S512G
GR-S462Q/GR-S462G
116
103
297
270
413
373
680(W) X 758(D) X 1725(H)
680(W) X 708(D) X 1725(H)
74
71
COOLING SYSTEM
Fan Cooling
TEMPERATURE FREEZER CONTROL REFRIGERATOR
Knob Dial Micom Control Full Automatic
DEFROSTING SYSTEM Heater Defrost OUT CASE
Coated Steel Sheet
INNER CASE
ABS
INSULATION
Polyurethane Foam
SHELF
FREEZER
1 EA
REFRIGERATOR
2 EA
VEGETABLE TRAY
Drawer Type
EGG TRAY
2 Pieces
ICE TRAY
1 Piece (*2)
ICE BANK
1 Piece
COMPRESSOR
P.T.C Starting Type
EVAPORATOR
Fin Tube Type
CONDENSER
Wire Condenser
REFRIGERANT
R134a (150g)
DEFROSTING DEVICE
Sheath heater
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2. PARTS IDENTIFICATION
FREEZER COMPARTMENT Lamp Freezer Temperature Control Dial
Freezer Door Rack
Freezer Shelf Twisting Ice Serve(Option) or General Type Ice Making
Egg Storage Rack
REFRIGERATOR COMPARTMENT
Wine Rack (Option if steel shelf) You can use this as Vodka rack in the Freezer.
Deodorizer (Option) Chilled Compartment Refrigerator Temperature Electronic Control
Bottle Guide
Lamp F.I.R Lamp (Option) Shelves (Plastic or Steel or Tempered Glass)
Refrigerator Door Rack
Multi Flow Duct Distributes cold air to each part of refrigerator compartment.
Leveling Screw
Vegetable Drawer Used to keep fruits and vegetables, etc. fresh and crisp.
Vegetable Partitioner (Option)
NOTE : This is a basic model. The shape of refrigerator is subject to change.
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3. DISASSEMBLY 3-1 DOOR
3-2 DOOR SWITCH
● Freezer
1. To remove the door switch, pull out it with a '—' type driver as shown in (figure 9). 2. Disconnect the lead wire from the switch.
Door 1. Remove the hinge cover by pulling it upwards. 2. Loosen hexagonal bolts fixing the upper hinge to the body and lift the freezer door. HINGE COVER BOLT HINGE
Figure 9 Figure 6
3-3 THERMISTOR 3. Pull out the door gasket to remove from the door foam Ass'y.
1. Remove the Cover Lamp-R by the use of '–––' type driver inserting in the low holes of the cover. 2. Loose 2 screw. 3. Pull the Control Box-R. 4. Disconnect the Housing of lead wire. 5. Separate the INSU'Multi Duct and Control Box-R. 6. Separate the Thermistor and Control Box-R. 7. Separate the Thermistor and Display PCB.
GASKET
INSU' MULTI DUCT THERMISTOR
Figure 7
CONT' BOX-R
DISPLAY PCB
Refrigerator Door 1. Loosen hexagonal bolts fixing the lower hinge to the body to remove the refrigerator door only.
●
COVER LAMP-R MOTOR FAN
COVER BLADE
FAN
Figure 10
LOWER HINGE
3.4 FAN AND FAN MOTOR 1. Remove the freezer shelf. 2. Separate the twist by pulling right. 3. Loosen 1 cap screw fixing the Grille Fan. 4. Loose 1 screw. 5. Pull out the Grille Fan and Shroud-F.
BOLT
Figure 8 2. Pull out the door gasket to remove from the door foam Ass'y.
Figure 11
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6. Disconnect the housing of lead wire. 7. Separate the Fan Assy. 8. Loose 2 screw fixed to the Bracket. 9. Pull out Shroud-F remove the Fan Motor Assy. 10. Separate the Motor Bracket and Rubber.
3-6 LAMP FREEZER ROOM LAMP
REFRIGERATOR ROOM LAMP
FAN MOTOR SHROUD
Figure 16
Figure 17
BRACKET
3-6-1 Freezer room lamp 1. Pull forward the lamp cover-F hole. 2. Remove the lamp-F by turning.
FAN GRILLE
Figure 12
3-6-2 Refrigerator room lamp 1. Remove the cover lamp-R by pulling with a '–––' type driver. 2. Remove the lamp-R by turning.
3-5 DEF' CONTROL ASM Def control ASM consists of Defrost Sensor and FUSE–M. Defrost Sensor functions to defrost automatically and it is attached to the Evaporator and the metal side of the case senses Temp. Fuse-M is a kind of safety device for preventing overheating of the Heater when defrosting. At the temperature of 77°C, it stops the emission of TEMP from the Defrost Heater. 1. Pull out the shroud-F after removing the Grille Fan. (Figure 13) 2. Separate the connectors connected with the Def Control ASM and replace the Def Control ASM after cutting the Tie Wrap. (Figure 14)
3-7 CONTROL BOX-R 1. Remove the Cover Lamp-R.
CONTROL BOX-R
COVER LAMP SHROUD-F
FAN
DEF CONTROL ASM
Figure 18
2. Loosen 2 screws. 3. Full the Control Box-R. 4. Separate the lead wire Housing. Figure 13
Figure 14
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4. ADJUSTMENT 4-2-3 PTC-Applied Circuit Diagram ● According to Starting Method of Motor
4-1 COMPRESSOR 4-1-1 Role The compressor inhales low temperature and low pressure gas evaporated from Evaporator of the Refrigerator, and condenses this gas to high temperature and high pressure gas, and then plays delivering role to Condenser.
OVERLOAD PROTECTOR C
4-1-2 Composition The Compressor is Composed of Compressor Apparatus compressing gas, Compressor Motor moving Compressor Apparatus and Case protecting Compressor Apparatus and Motor. There are PTC-Starter, and Over Load Protector (OLP) in the Compressor outside. On the other hand, because the Compressor consists of 1/1000mm processing precision components and is sealed after producing without dust or humidity, deal and repair with care.
PTC
5 S
3
6
PTC STARTER
COMPRESSOR MOTOR M M S HERMETIC TERMINAL
RSIR
Figure 20
4-1-3 Note to Use (1) Be careful not to allow over-voltage and over-current. (2) No Strike If applying forcible power or strike (dropping or careless dealing), poor operation and noise may occur. (3) Use proper electric components appropriate to the Compressor. (4) Note to Keep Compressor. If Compressor gets wet in the rain and rust in the pin of Hermetic Terminal, poor operation and poor contact may cause. (5) Be careful that dust, humidity, and flux due to welding don't inflow in Compressor inside in replacing Compressor. Dust, humidity, and flux due to welding which inflows to Cylinder may cause lock and noise.
4-2-4 Motor Restarting and PTC Cooling (1) For restarting after power off during normal Compressor Motor operation, plug the power cord after 5 min. for pressure balance of Refrigerating Cycle and PTC cooling. (2) During normal operation of Compressor Motor, PTC elements generate heat continuously. Therefore, if PTC isn't cooled for a while after power off, Motor can't operate again. 4-2-5 Relation of PTC-Starter and OLP (1) If power off during operation of Compressor and power on before PTC is cooled, (instant shut-off within 2 min. or reconnect a power plug due to misconnecting), PTC isn't cooled and a resistance value grows. As a result, current can't flow to the sub-coil and Motor can't operate and OLP operates by flowing over current in only main-coil. (2) While the OLP repeats on and off operation about 3-5 times, PTC is cooled and Compressor Motor performs normal operation. If OLP doesn't operate when PTC is not cooled, Compressor Motor is worn away and causes circuitshort and fire. Therefore, use a proper fixed OLP without fail.
4-2 PTC-STARTER 4-2-1 Composition of PTC-Starter (1) PTC (Positive Temperature Coefficient) is no-contact semiconductor starting device which uses ceramic material and the material consists of BaTiO3. (2) The higher the temperature is, the higher resistance value becomes . These features are used as starting device of Motor.
4-2-6 Note to Use PTC-Starter (1) Be careful not to allow over-voltage and over-current. (2) No Strike Don't apply a forcible power or strike. (3) Keep apart from any liquid. If liquid such as oil or water inflows into PTC, PTC materials it may break due to insulation breakdown of material itself. (4) Don't change PTC at your convenience. Don't disassemble PTC and mold. If damaging to outside of PTC-starter, resistance value alters and poor starting of compressor motor may cause. (5) Use a properly fixed PTC.
4-2-2 Role of PTC-Starter (1) PTC is attached to Hermetic Compressor used for Refrigerator, Show Case and starts Motor. (2) Compressor for household refrigerator applies singlephase induction Motor. For normal operation of single-phase induction motor, in the starting operation flows in both main coil and subcoil. After the starting is over, the current is cut off in subcoil. The proper features of PTC play the above all roles. So, PTC is used as a starting device of motor.
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4-3 OLP (OVER LOAD PROTECTOR)
CONTACTING POINT
4-3-1 Definition of OLP (1) OLP (OVER LOAD PROTECTOR) is attached to Hermetic Compressor and protects Motor by cutting off current in Compressor Motor by Bimetal in the OLP in case of over-rising temperature. (2) When over-voltage flows to Compressor motor, Bimetal works by heating the heater inside OLP, and OLP protects Motor by cutting off current which flows to Compressor Motor.
COVER BIMETAL
CONTACTING POINT HEATER TERMINALS
4-3-2 Role of OLP (1) OLP is attached to Hermetic Compressor used to Refrigerator and Show Case and prevents Motor Coil from being started in the Compressor. (2) Do not turn the Adjust Screw of OLP in any way for normal operation of OLP. (Composition and connection Diagram of OLP)
BIMETAL ADJUST SCREW
HEATER
5. CIRCUIT DIAGRAM CIRCUIT DIAGRAM
NOTE : 1. This is a basic diagram and specifications vary in different localities.
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Figure 21
6. TROUBLESHOOTING 6-1 COMPRESSOR AND ELECTRIC COMPONENTS
1
Power Source.
Remove the PTC-Starter from the Compressor and measure the voltage between Terminal C of Compressor and Terminals 5 or 6 of PTC.
(Rating Voltage ±10%)?
No Voltage.
OLP disconnected?
YES
2
YES
Replace OLP.
5
Check connection condition.
Reconnect.
Advise the customer to use a regular Trans.
Applied voltage isn't in the range of Rating Voltage ±10%.
2
3
Check the resistance of Motor Compressor.
Check the resistance among M-C, S-C and M-S in Motor Compressor.
Check the resistance of PTC-Starter.
Check the resistance of two terminals in PTC-Starter.
Check OLP.
Check if applying a regular OLP.
5
YES
3
NO Replace Compressor.
3
4
YES
5 4
Replace PTC-Starter.
NO
5
YES
4
OLP works within 30 sec. in forcible OLP operation by turning instant power on and off.
YES NO
5
Replace OLP.
NO
5
Check starting state.
Measure minimum starting voltage after 5 min. for balancing cycle pressure and cooling the PTC.
Components start in the voltage of Rating Voltage ±10% below.
YES
O.K.
NO
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1
6-2 PTC AND OLP Separate the PTC from Compressor and measure the resistance between No. 5 and 6 (only RSIR Type) or No. 4 and 5 of PTC with a Tester or Whistone Bridge. (Figure 22)
Observation value is 220V/50Hz : 22Ω±30% 115V/60Hz : 6.8Ω±30% 240V/50Hz : 33Ω±30% 127, 220V/60Hz : 22Ω±30%
Check another electric components.
The resistance value is 0 or several hundreds Ω.
Replace PTC.
The value is ∞.
Separate the OLP from Compressor and check resistance value between two terminals of OLP with a Tester. (Figure 23)
YES
Check another electric components.
NO
Replace OLP.
4 5
6
Normal operation of Compressor is impossible or poor.
3
Figure 23
Figure 22
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6-3 ANOTHER ELECTRIC COMPONENTS ▼ Cooling is impossible Compressor doesn't run.
Running state of Compressor is poor.
Check if current flows to the following components.
Cause.
a. Thermistor
Poor contacting.
b. Starting devices
Shorted or broken.
c. OLP
Poor contacting or shorted.
d. Compressor coil
Coil shorted.
e. Circuit Parts
Poor contacting or shorted.
Replace each component.
Check a starting voltage.
Low voltage.
Raise the voltage.
Check if current flows to starting devices.
Poor contacting and broken.
Replace each component.
Check current flowing in sub-coil of Compressor.
Shorted.
Check capacity of OLP.
Lack of capacity.
The items described above are normal.
Coil of motor Compressor.
Check current flowing in door S/W.
Poor contacting.
Check current flowing in the Fan Motor.
Coil is shorted.
Replace the compressor.
▼ Cooling ability is poor
Fan motor doesn't run.
Much frost are sticked to the EVAPORATOR.
Replace each component.
Check current flowing of the following components. • Def. Sensor • FUSE-M
Shorted.
Check current flowing of the following components. • Sheath Heater
Replace each component.
Replace each component.
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6-4 SERVICE DIAGNOSIS CHART COMPLAINT
POINTS TO BE CHECKED
Cooling is impossible.
• Is the power cord unplugged from the outlet? • Check if the power S/W is set to OFF. • Check if the fuse of power S/W is shorted. • Measure the voltage of power outlet.
• Plug to the outlet. • Set the switch to ON. • Replace a regular fuse. • If voltage is low, wire newly.
Cooling ability is poor.
• Check if the set is placed close to wall. • Check if the set is placed close to stove, gas • cooker and direct rays. • Is the ambient temperature high or • the room door closed? • Check if putting in hot foods. • Did you open the door of the set too often • or check if the door is closed up? • Check if the Control is set to "Min".
• Place the set with the space of about 10cm. • Place the set apart from these heat • appliances. • Make the ambient temperature below.
Foods in the Refrigerator are frozen.
• Are foods placed in cooling air outlet?
• Put in foods after they get cold. • Don't open the door too often and close • it firmly. • Set the control to mid-position.
• Check if the Display LED is set to "Max". • Is the ambient temperature below 5°C?
• Place foods in high temperature section. • (Front Part) • Set the Display LED to "Mid". • Set the Display LED to "Min".
Dew or ice forms in the chamber of the set.
• Is watery foods kept? • Check if putting in hot foods. • Did you open the door of the set too • often or check if the door is closed up.
• Seal up watery foods with wrap. • Put in foods after they get cold. • Don't open the door too often and close • it firmly.
Dew forms in the Out Case.
• Check if ambient temperature and humidity of surroumcling air are high.
• Wipe dew with a dry cloth. This happening • is solved in low temperature and humidity • naturally. • Fill up the gap.
• Is the gap in the door packed? Abnormal noise generates.
• Is the set positioned in a firm and even place? • Does any unnecessary objects exist • in the back side of the set? • Check if the Drip Tray is not firmly fixed. • Check if the cover of mechanical room • in below and front side is taken out.
To close the door is not handy.
• Check if the door packing becomes dirty • by filth such as juice. • Is the set positioned in a firm and even place? • Is too much food putted in the set?
Ice and foods smell unpleasant.
●
REMEDY
• Check if the inside of the set becomes dirty. • Did you keep smelly foods without wraping? • It smells plastic.
• Adjust the Adjust Screw, and position • in the firm place. • Remove the objects. • Fix it firmly on an original position. • Place the cover at an original position. • Clean the door packing. • Position in the firm place and adjust the • Adjust Screw. • Keep foods not to reach the door. • Clean the inside of the set. • Wrap smelly foods. • The new products smell plastic, but it is • removed after 1-2 weeks.
In addition to the items described left, refer to the followings to solve the complaint. Check if dew forms in the Freezer.
Defrosting is poor.
Replace the Components of defrosting circuit.
Check Refrigerating Cycle.
The cycle is faulty.
Repair the cycle.
Check the Thermistor
The operation of the Thermistor is poor.
Replace the Thermistor.
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6-5 REFRIGERATING CYCLE ▼ Troubleshooting Chart
STATE OF THE SET
CAUSE
STATE OF THE EVAPORATOR
TEMPERATURE OF THE COMPRESSOR
REMARKS
LEAKAGE CLOGGED BY DUST
PARTIAL LEAKAGE
Freezer and Refrigerator don't get cold normally.
Low flowing sound of Refrigerant is heard and frost forms in inlet only
A little high more than ambient temperature.
• A little Refrigerant • discharges. • Normal cooling is possible • when injecting Refrigerant • of regular amount.
WHOLE LEAKAGE
Freezer and Refrigerator don't get cold at all.
Flowing sound of Refrigerant is not heard and frost isn't formed.
Equal to ambient temperature.
• No discharging of Refrigerant. • Normal cooling is possible • when injecting Refrigerant • of regular amount.
PARTIAL CLOG
Freeze room and Refrigerator don't get cold normally.
Flowing sound of Refrigerant is heard and frost forms in inlet only.
A little high more than ambient temperature.
• Normal discharging of • refrigerant. • The capillary tube is faulty.
WHOLE CLOG
Freezer and Refrigerator don't get cold.
Flowing sound of Refrigerant is not heard and frost isn't formed.
Equal to ambient temperature.
• Normal discharging of • Refrigerant.
Cooling operation stops periodically.
Flowing sound of Refrigerant is not heard and frost melts.
Low than ambient temperature
• Cooling operation restarts • when heating the inlet of • capillary tube.
COMPRESSION
Freezer and Refrigerator don't get cold.
Low flowing sound of Refrigerant is heard and frost forms in inlet only.
A little high than ambient temperature.
• The pressure of high • pressure part in • compressor is low.
NO COMPRESSION
No compressing operation.
Flowing sound of Refrigerant is not heard and no frost.
Equal to ambient temperature.
• No pressure of high pressure • part in compressor.
MOISTURE CLOG DEFECTIVE COMPRESSION
▼ Leakage Detection Observe discharging point of refrigerant which may be in oil discharging part in compressor and hole of evaporator.
Whether Compressor runs or not.
YES
Whether frost forms or not in Evaporator.
Normal formed frost
No frost or forms in inlet only
Whether oil leaks or not.
Observe the discharging amount of Refrigerant.
Normal amount
No or much amount Moisture Clog.
Faulty Compressor.
Check Comprossor
YES
Inject Refrigerant to Compressor and check cooling operation.
Clogged by dust.
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Gas leakage. Normal formed frost in Evaporator (Check the leakage point)
▼ General Control of Refrigerating Cycle
NO.
ITEMS
CONTENTS AND SPECIFICATIONS
WELDING ROD
(1) H 30 (1) • Chemical Ingredients (1) • Ag: 30%, Cu: 27%, Zn: 23%, Cd: 20% (1) • Brazing Temperature: 710~840°C (2) Bcup-2 (1) • Chemical Ingredients (1) • Cu: About 93% (1) • P: 6.8~7.5% (1) • The rest: within 0.2% (1) • Brazing Temperature: 735~840°C
FLUX
(1) • Ingredients and how to make (1) ••Borax 30% (1) ••Borax 35% (1) • Fluoridation kalium: 35% (1) • Water: 4% (1) • Mix the above ingredients and boil until (1) • they are transformed into liquid.
• Make amount for only a day. (1) • Holding period: 1 day • Close the cover of container to prevent dust • putting in the FLUX. • Keep it in a stainless steel container.
DRIER ASM
(1) Assemble the drier within 30min. (1) after unpacking. (2) Keep the unpacked drier at the temperature of 80~100°C.
• Don't keep the drier in a outdoor because • humidity damages to it.
VACUUM
(1) When measuring with pirant Vacuum (1 )gauge of charging M/C, vacuum (1 )degree is within 1 Torr. (2) If the vacuum degree of the cycle inside is (2) 10 Torr. below for low pressure and 20 Torr. (2) for high pressure, it says no vacuum (2) leakage state. (3) Vacuum degree of vacuum pump must be (3) 0.05 Torr. below after 5 min. (4) Vacuum degree must be same to the value described item (2) above for more than 20 min.
• Apply M/C Vacuum Gauge without fail. • Perform vacuum operation until a proper • vacuum degree is built up. • If a proper vacuum degree isn't built up,• • check the leakage from • the Cycle Pipe line part and • Quick Coupler Connecting part.
DRY AND AIR NITROGEN GAS
(1) The pressure of dry air must be more than 12~16Kg/cm2 (2) Temperature must be more than -20~-70°C. (3) Keep the pressure to 12~6Kg/cm2 also (3) when substituting dry air for Nitrogen Gas.
NIPPLE AND COUPLER
(1) Check if gas leaks with soapy water. (2) Replace Quick Coupler in case of leakage.
PIPE
(1)• Put all Joint Pipe in a clean box and (1)• cover tightly with the lid so that dust or (1)• humidity is not inserted.
1
2
3
4
5
6
7
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REMARKS • Recommend H34 containing 34% Ag in the • Service Center.
• Check if gas leaks from connecting part of • Coupler.
7. DESCRIPTION OF FUNCTION & CIRCUIT OF MICOM The following description is basically for GR-S462/GR-S512. For the other models, refer to the diagram of the entire PCB circuit.
7-1 FUNCTION 7-1-1 FUNCTION 1. When the appliance is plugged in, it is set to ‘Medium’. Each time the button is pushed, it is set to ‘Medium’→‘Medium/High’→‘High’→‘Low’→‘Medium/Low’→‘Medium’ in order. 2. When the power is initially applied or restored after a power failure, it is automatically set to ‘Medium’.
Low
Medium/ Low
Medium
Medium/ High
2
0
High
Temp Control TEMP(˚C) ROOM
7
4
REFRIGERATOR
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-2
7-1-2 DEFROSTING 1. The defrosting is performed each time when the total running time of the compressor reaches 7 hours. 2. After the power is turned on (or restored after a power failure), the defrosting starts when the total running time of the compressor reaches 4 hours. 3. When the temperature of the defrosting sensor reaches 10 °C or above, the defrosting stops. If the temperature does not reach 10 °C in 2 hours after the defrosting starts, the defrosting error code is displayed. (Refer to 7-1-5 Error Diagnostic Mode.) 4. With the defective defrosting sensor (cut or short-circuited wire), the defrosting will not be performed.
7-1-3 SEQUENTIAL OPERATION OF ELECTRIC COMPONENTS The electric components, such as the comp, defrosting heater, and cooling fan, start sequentially to avoid the noise and damage to the part, which may result from the simultaneous start of various components on turning the power on or after the completion of a test.
Condition of Operation When the power is turned on
If the temp of the defrosting sensor is 45 °C or above (For the initial use after the purchase or grounding)
If the temp of the defrosting sensor is below 45 °C (After a power failure or SVC)
Operating Sequence
POWER ON
POWER ON
in 0.5 sec
in 0.5 sec
in 0.5 sec
COMP & COOLING FAN ON
DEFROSTING HEATER ON
in 10 sec
DEFROSTING HEATER OFF
COMP & COOLING FAN ON
7-1-4 CONTROL OF DOUBLE COOLING FAN IN THE REFRIGERATOR COMPARTMENT. 1. To raise the refrigerating speed, Fan Motor in the Refrigerator Compartment is operated when the door of freezer room or refrigerator room is opened and then closed. 2. The Fan Motor is stoped after 20 sec. when the door is closed.
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7-1-5 ERROR DIAGNOSTIC MODE 1. The error diagnostic mode allows the SVC when a fault that may affect the performance of the product occurs while operating the product. 2. Even if the function control button is pushed when an error occurs, the function will not be performed. 3. When the error is cleared while the error code is displayed due to a fault, the appliance returns to the normal condition (Reset). 4. The error code is displayed by the refrigerator temp indication LED on the display of the refrigerator while the remaining LEDs are off.
R1 R2 R3 R4
: ON NO
Error
Error Code Display R1
R2
R3
Cause
R4
State of Operation with Error Comp / Cooling fan
1.
Faulty refrigerator(R) sensor (on the control box of the refrigerator)
Cut or short-circuited wire of refrigerator sensor
2.
Faulty defrosting sensor
Cut or short-circuited wire of defrosting sensor
3.
Defrosting failure
Cut or disconnected wire of defrosting heater or temperature fuse(indicated at least 2 hours later after the error occurs)
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: OFF
Defrosting heater
15 min ON/ 15 min OFF
No defrosting
7-2 PCB FUNCTION 7-2-1 POWER CIRCUIT
The secondary part of the TRANS is composed of the power supply for the display and relay drive (12Vdc) and that for the MICOM and IC (5Vdc). The voltage for each part is as follows. PART
VA 1
CE 2
CE3
VOLTAGE
220 Vac
12 Vdc
5 Vdc
VA1 is a part for preventing the over voltage and noise. When 385V or higher power is applied, the inside elements are short-circuited and broken, resulting in the blowout of the fuse in order to protect the elements of the secondary part of the TRANS.
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7-2-2 OSCILLATION CIRCUIT
This circuit is to generate the base clock for calculating time and the synchro clock for transmitting data from and to the inside logic elements of the IC1(MICOM). Be sure to use the authentic parts since the calculating time by the IC1 may be changed or it will not work if the OSC1 SPEC is changed.
7-2-3 RESET CIRCUIT
The RESET circuit is for allowing all the functions to start at the initial conditions by initializing various parts including the RAM inside the MICOM (IC1) when the power is initially supplied or the power supply to the MICOM is restored after a momentary power failure. For the initial 10ms of power supply, ‘LOW’ voltage is applied to the MICOM RESET terminal. During a normal operation, 5V is applied to the RESET terminal. (If a trouble occurs in the RESET IC, the MICOM will not work.)
- 20 -
7-2-4 LOAD DRIVE CIRCUIT 1. Load Drive Condition Check
Comp, Freezer Fan Motor
Load Type Measurement Location(IC5) Condition
No.13
Defrosting Heater
Refrigerator Fan
No.10
No.12
ON
1V or below
OFF
12V
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7-2-5 TEMPERATURE SENSOR CIRCUIT
The upper CIRCUIT reads REFRIGERATOR temperature and DEF-SENSOR temperature for defrosting into MICOM. OPENING or SHORT state of each TEMPERATURE SENSOR are as follows. SENSOR
CHECK POINT
Refrigerator Sensor
POINT A Voltage
Defrosting Sensor
POINT B Voltage
NORMAL(-30 °C ~ 50 °C)
SHORT-CIRCUITED
OPEN
0.5 V ~ 4.5 V
0V
5V
7-2-6 DOOR OPEN DETECTING CIRCUITS
MEASURING POINTS
IC1 (Pin No. 8)
Freezer / Refrigerator Door CLOSED
5V
OPEN
0V
- 22 -
7-2-7 TEMPERATURE COMPENSATION & OVERCOOLING/UNDERCOOLING COMPENSATION CIRCUIT 1. Refrigerator Temperature Compensation
Refrigerator Resistance
Temperature
(RCR1)
Compensation
180 KΩ
+2.5 °C
56 KΩ
+2.0 °C
33 KΩ
+1.5°C
18 KΩ
+1.0 °C
12 KΩ
+0.5 °C
10 KΩ
0 °C
Standard Temperature
8.2 KΩ
-0.5°C
Compensation by lowering the temperature
5.6 KΩ
-1.0°C
3.3 KΩ
-1.5 °C
2 KΩ
-2.0 °C
470 Ω
-2.5 °C
Remark Compensation by raising the temperature
➧ Table of Temperature Compensation by adjusting the resistance (Difference with the current temperature) E.g.) If the refrigerator compensation resistance (RCR1) is changed from 10K (the current resistance) to 18K (the adjustment resistance), the temperature of the refrigerator rises +1 °C.
- 23 -
7-2-8 KEY BUTTON INPUT & DISPLAY LIGHT ON CIRCUIT
➧ The circuit shown above is to determine whether a function control key on the operation display is pushed and to turn on the corresponding function indication LED. The drive type is the scan type.
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7-3 RESISTANCE SPECIFICATION OF SENSOR TEMPERATURE SENSOR
RESISTANCE OF REFRIGERATOR (DEFROST) SENSOR
- 20 ˚C
77 KΩ
- 15 ˚C
60 KΩ
- 10 ˚C
47.3 KΩ
- 5 ˚C
38.4 KΩ
0 ˚C
30 KΩ
+ 5 ˚C
24.1 KΩ
+ 10 ˚C
19.5 KΩ
+ 15 ˚C
15.9 KΩ
+ 20 ˚C
13 KΩ
+ 25 ˚C
11 KΩ
+ 30 ˚C
8.9 KΩ
+ 40 ˚C
6.2 KΩ
+ 50 ˚C
4.3 KΩ
• The resistance of SENSOR has ±5% common difference. • Measure the resistance of SENSOR after leaving it over 3 minutes in measuring temperature. This postponing is necessary because of perceiving speed. • Measure the F-SENSOR, SUPER FROST SENSOR, R1, R2-SENSOR after disconnect CON5 of PWB ASSY, MAIN.
- 25 -
7-4 TROUBLE SHOOTING • Replace PCB when no trouble after checking the contents of trouble.
STATE OF TROUBLE
POINT BE CHECKED
CHECKING METHOD
POWER SOURCE is poor
1. All the DISPLAY LED OFF 2. DISPLAY LED represents abnormal operation.
1. FREEZER/ REFRIGERATOR 2. LAMP is dim. 3. The connection of CONNECTOR of MAIN PWB.
FREEZER/REFRIGERATOR DOOR OPEN CHECK with the naked. Certify connection of CONNECTOR.
COOLING is poor
NO COOLING
1. COMPRESSOR operates?
2. Whether refrigerant leaks or leaks or not.
FREEZER TEMPERATURE is poor
1. Whether FAN MOTOR operates or not.
2. DEFROSTING normal? 3. SENSOR normal?
Check the MAIN PCB.
Measure the amount of frost sticking on EVA and the surface temperature of condenser pipe. Check the MAIN PCB.
Certify the amount of frost sticking on EVA. Check resistance the SENSOR in the Refrigerator
CONTENT POWER SOURCE is poor Applied voltage mistake CONNECTOR connection is poor. TRANS FUSE open. COMPRESSOR lock or blocked. OLP, PTC is poor. COMPRESSOR RELAY is poor THE CONNECTING WIRE is poor. Refrigerant leakage.
REMEDY Certify Fuse. Certify outlet Voltage. Use boosting TRANS. Reconnect CONNECTOR. Replace TRANS. Replace COMPRESSOR. Replace OLP, PTC. Replace MAIN PWB RY1 Certify the black wire of MAIN PWB CONNECTOR (CON1) Remedy the leaking part and reaching Refrigerant.
FAN MOTOR is poor DOOR LINE contact. CONETTING WIRE is poor.
Replace FAN MOTOR. Replace DOOR LINER. Certify MOTOR and the connection of the black wire of MAIN PWB CONNECTOR. (CON1)
DEFROSTING is poor.
See the DEFROSTING trouble. Replace SENSOR
SENSOR RESISTANCE is poor.
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CLASSIFICATION
CLASSIFICATION
STATE OF TROUBLE
COOLING is poor.
REFRIGERATOR TEMPERATURE is poor.
POINT BE CHECKED 1. FREEZER TEMPERATURE is normal? 2. Cool air of FAN MOTOR is is sufficient?
CHECKING METHOD
CONTENT
REMEDY
See "FREEZER
Certify the attaching state
TEMPERATURE is poor".
of DOOR.
Certify the amount of cool air
FAN MOTOR is poor.
Replace FAN MOTOR.
and its speed touching check
Passage of cool air blocking.
Remove impurities.
REFRIGERATOR
EVA frozen.
See "DEFROSTING is poor".
Check the MAIN PCB.
HEATER disconnection.
Replace HEATER.
TEMPERATURE FUSE disconnection. Connection is poor.
Replace TEMPERATURE FUSE. Certify EVA connection and wire of MAIN PWB CONNECTOR (CON1) Replace DEF-SENSOR. Replace RY4 of MAIN PWB. Remove ice and impurities. Certify HEATER PLATE resistance. Reassemble DEF-SENSOR.
DEFROSTING is poor.
NO DEFROSTING.
1. HEATER emit heat?
2. DRAIN PIPE blocking?
Certify DRAIN PIPE.
3. Remain ice at DEFROSTING?
Certify the attaching of DEF-SENSOR. Certify the attaching state(gap) of FREEZER/ REFRIGERATOR DOOR.
DEF-SENSOR is poor. HEATER RELAY is poor. DRAIN PIPE blocking.
Attaching is poor. DOOR sticking is poor.
Reassemble DOOR. Replace GASKET.
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supplied into
7-5 MAIN PWB ASSEMBLY AND PARTS LIST 7-5-1 MAIN PWB ASSEMBLY
- 28 -
7-5-2 REPLACEMENT PARTS LIST
- 29 -
7-5-3 PWB ASSEMBLY, DISPLAY AND PARTS LIST
- 30 -
7-6 PWB DIAGRAM
- 31 -
REF. TEMP. CONTROL
- 32 -
8. EXPLODED VIEW ▼ The parts of refrigerator and the shape of each part are subject to change in different localities. ▼ Capacitors and fuse are optional parts. ▼ : Optional parts.
*
1) Freezer Shelf -Plastic : 149A -Steel : 136C, 136D 2) Ice Maker - Twist : 110B, 125A, 125H, 131A - Standard : 125J 3) Refrigerator Shelves - Plastic: 149C - Steel : 136A, 136B, 149D
103B
301A 281A
281B
103A
401A 129A
501F 411A
418A
501A
*
410G
*
125L
410H 282B
*
501K
409A
410J 406B
282J
* *
304A
158B
*
604E 604F
158A
120A
105A
409B
317A 318A
409C 310A
307A
283B 314A 308A 309A
323B
329C
329D
158C
106B
420A 312A
106A
104C
158F
315A
327A 319C
103C 109B
328A
324A
319A 315B
315C
- 33 -
405C 405A
330B 404A 329A
332A
* *
149D
110B
* * *
125A
*
131A
*
125H
136C
125J
*
*
149A 149B
136D
140A
149C
* * * * * *
149C
136A
136B
149C
149C
136A
136B
154A
155B
151A
- 34 -
205A 200A
203A
201A
*
205A
201A 212G
* 212A 212C 212A 212C 235A
210A
210A
241A
230A 233A
231A 237A 233B 231A 233B
241C 244A 244C
241A
244A 244C
241D
210A
210A
- 35 -
212G
